* KBA recommends using Planeta universal splints or Ternes splints for glazing blankets, and automatic splints without lining splints for shiny stencils.
* The combined pressure between the anilox roller and the polishing plate cylinder should be as low as possible.
Printing bright oil
* According to Fogra, the ghosting caused by the oil particles in the ink reacting with the reverse side of the substrate in the stack can be prevented by applying water-based varnish. It is recommended not to use imprinted varnish for this purpose, because it will only make ghosts worse.
* The boundary of the surface tension of the granular lacquered lacquer is much higher than that of the gloss varnish. This must be taken into consideration when selecting the substrate.
Water-based varnish
* Only use solvent-resistant and alkali-resistant printing inks in accordance with DIN 16524 (Schmid-Rhyner's SRAG test solution can be used for inspection if necessary). Do not use delayed drying or scratch-resistant ink, or anti-friction paste. Fresh and overnight inks are also not suitable. The ink should be free of surfactants, such as wax or silicone; in waterless offset printing, it is a standard procedure to apply silicone oil-free glaze to the ink.
* If it dries too fast after being applied to a thick layer of ink, the ink film will crack. This defect can be corrected by reducing the power of the drying device or printing at a higher speed, increasing the amount of varnish applied, adding a retarder, or using a different varnish.
* In the process of glazing on both sides, the ink may collect on the glazing plate. The amount of varnish can be increased to correct this defect.
* When processing some images, the glazing oil may collect on the glazing plate, so manual cleaning may be necessary. Matte varnishes are particularly prone to this situation.
* The streaks in the matte gloss varnish caused by mineral ingredients can be corrected by agitating the varnish.
* If the surface tension of the substrate or ink is too low (should be at least 35 mN · m), appropriate varnish additives should be used. On the contrary, if the varnish cannot relax properly, a surfactant should be added.
* If the varnish is operated below the minimum film forming temperature, it will form an orange peel surface. This can happen if the storage temperature of the varnish is too low or not adjusted properly, or if the air blown onto the varnish is too cold.
* Poor wear resistance (nail testing, laboratory friction slide) indicates that the setting of the drying device is too low to form a film. Generally, if the varnish cannot be completely dried, the power of the radiator should be increased.
* The brittleness of the varnish film indicates that the scratch resistance is not good. The answer is to use a more flexible varnish. If the ink containing silicone or wax is the cause of this situation, use a different ink.
* If a varnish has not been thoroughly stirred, it must be stirred again. Any printed sheet with a thin varnish layer should be re-glazed.
* The foam does not have to be caused by the anilox roller or scraper cavity. Therefore, to check whether the pumping system has sucked in air, it may be necessary to add a suitable defoamer.
* If the substrate is too absorbent, seal the surface with a primer before applying the specified varnish to achieve the required gloss level. Of course, it is best to choose the right paper from the beginning.
* Be sure to prepare for the decrease in viscosity caused by the increase in temperature during high-speed operation of the printing press. If the initial varnish viscosity is set at the lower limit of 25s (DIN 4 flow cup), there is no reserve. However, when used with high-speed online glazing, excessively high viscosity can cause splashing. The viscosity can be kept constant with a rotary viscometer.
* The occurrence of sticking in the paper stack indicates that the time for the printed sheet to pass through the drying device is too long (this may be because the varnish contains too many additives to prevent it from cracking) which causes the temperature of the paper stack to be too high. If the gloss glazing oil formulated for double-sided glazing is used for single-sided glazing, it may also cause sticking due to the glass plate effect (the vacuum is generated between the sheets to press them tightly together).
* When the shutdown time is longer, the varnishing unit should continue to run to prevent the varnish from drying out.
* Glossing metallic inks (even with primers) may cause discoloration and flaking. It is necessary to carry out some experiments in cooperation with the varnish manufacturer.
UV varnish
* The second varnish line eliminates the risk of water contamination when performing a compound operation with water-based varnish. Water will prevent the UV varnish from curing.
* If the problem of sticking pages or odors occurs repeatedly in the stack, this indicates that it has not been properly cured (test hardness). The reason may be that the printing speed is too high, the reflector is dirty, damaged or the lamp is aging.
* If the varnish cannot be spread even with sufficient sustained parts, it may be that the UV varnish becomes too viscous because it is too cold. Warming the varnish should work. This can be done by the heater in the varnish circulation system or by infrared radiation in the continuous section. Another reason may be that the temperature of the stack is too low. If the amount of varnish applied is too large, it may cause cloudiness and hinder spreading.
* When used with water-based varnish, if the surface tension of the substrate is too low, it can be offset by appropriate glazing additives and by avoiding the use of surfactant-based inks.
* If you want to use offline UV glazing on paper printed with standard ink, you must remove the powder on the printed sheet. If the ink is not completely dry, the primer must be applied before applying UV varnish.
* On dual glazing presses, the primer and UV varnish must come from the same supplier. Blistering varnish
* Bubbling varnishes are usually water-based and thus compatible with similar inks like water-based varnishes. They can be used with all types of inks with similar thermal sensitivity recommended above. Occasionally, solvent-based blistering varnishes that heat seal faster are also used.
* Bubbling varnish can only be heat-sealed on hard elastic type membranes, such as PET (G, A) or PVC. Recycled cardboard is the best type to use. (Scotch tape test on raw materials: Cardboard varnish must tear off the cardboard fibers, because the varnish should always penetrate into the fibers.) The suitability of the cardboard for blistering varnish should be determined by the supplier.
* In order to ensure that the glazing oil film and the plastic film are properly sealed, the application amount should not exceed 6-8 g / m2. For some high-absorbency paperboard or heat-sealing of paperboard and paperboard, it may be necessary to apply varnish twice. In some cases it is more economical to apply the primer for the first time, because it is cheaper, and it is more effective at sealing the cardboard surface than blistering varnish.
* Low-power infrared radiation must be used to ensure that the blistering varnish will not be "heat-sealed" in the printing press.
* Bubbling varnish tends to block the surface of the anilox roller and the varnish conveying device, so the system must be thoroughly cleaned after printing operation. If production is interrupted for a period of time, the anilox roller should also be cleaned. The same requirements apply for special effect varnishes.
* The ideal storage temperature and relative humidity of the box board before printing operation and the blister card and varnish after printing are 18-25 ° C (64-77 ° F) and 55%, respectively. Weilburger found that if stored well, foam cards like these made with Senolith-WL foam varnish can be used for up to two years. If the storage conditions are not ideal, as long as they adapt to changes in the environment in advance, they can usually be processed without problems.
* Use the packaging machine to heat seal the blister card on the surface. The quality of the heat seal depends on the temperature, the compression pressure and the plane parallelism of the heat seal tool and the length of the thermal contact (machine timing), which is based on the thickness of the cardboard, the length of the heat seal tool, the type of diaphragm and the thickness of the varnish Fixed.
Varnishes and aromatic varnishes with special effect pigments
* Special effect pigments can be mixed in water-based and UV varnishes, and aromatic varnishes must be water-based. When choosing an anilox roller, the size of the particles must be considered. Rainbow pigments (up to 200 microns) and scented capsules (up to 30 microns) require the mesh to be 1.5 times the mesh size of the anilox roller.
* When working, the varnish with special effect pigments must be fully agitated, and the aromatic varnish must also be cooled.
* Aromatic varnish is very expensive (1 kg cost up to 500 euros), but it can be used sparingly and can be easily diluted. It is recommended to consult with the varnish manufacturer on the best method for handling and applying the varnish. As an option, the "spacer" can be mixed in the aromatic varnish to prevent the tiny capsules from being crushed when the varnish is applied and in the paper stack.
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